Apparatus for cell constructions



Nov. 21, 1961 J. v. CARLISLE ETAL 3,009,239

APPARATUS FOR CELL CONSTRUCTIONS 5 Sheets-Sheet 1 Original Filed March 9, 1955 //vvEN7'0/?$ JAMES M CARL/$1.5

THEODORE ,u. ARNOL 0 ATTORNEY Nov. 21, 1961 J. v CLARLISLE ET AL 3,009,239

APPARATUS FOR CELL CONSTRUCTIONS Original Filed March 9, 1955 5 Sheets-Sheet 2 IIVVEIVTORS JAMES V. CARL 5L THEODORE MJJAV D ATTORNEY Nov. 21, 1961 J. v. CARLISLE ETAL 3,009,239

APPARATUS FOR CELL CONSTRUCTIONS Original Filed March 9, 1955 5 Sheets-Sheet 5 INVENTORS JAMES M. CARL ISLE THEODORE M. ARNOLD F 6. 3 BY ATTORNEY Nov. 21, 1961 J. v. CARLISLE ET AL 3,009,239

APPARATUS FOR CELL CONSTRUCTIONS Original Filed March 9, 1955 5 Sheets-Sheet 4 II/IIII/IIIIIIII IN V EN TOR3 JAMES ll. CARL ISLE BY THE ODORE M. ARNOLD ATTORNEY Nov. 21, 1961 J. v. CARLISLE ET AL 3,009,239

APPARATUS FOR CELL CONSTRUCTIONS Original Filed March 9, 1955 5 Sheets-Sheet 5 I24 /2/ I22 I00 IN VEN TORS JAMES V. CARL/SL5 BY THEODORE M. ARNOLD ATTORNEY United States Patent fifice 3,009,239 Patented Nov. 21, 1961 APPARATUS FOR CELL CONSTRUCTIONS James V. Carlisle, Baton Rouge, La., and Theodore M.

Arnold, Kalamazoo, Mich., assignors to Ethyl Corporation, New York, N.Y., a corporation of Delaware Original application Mar. 9, 1955, Ser. No. 493,156, now

Patent No. 2,912,750, dated Nov. 17, 1959. Divided and this application Jan. 30, 1958, Ser. No. 715,171

3 Claims. (Cl. 29-203) This invention pertains to a new and novel method for the construction of electrolytic cells and in particular is concerned with an apparatus to be employed in the construction of these cells.

This application is a division of Application No. 493,156, filed March 9, 1955, now Patent No. 2,912,750.

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell which is basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, the cell includes a housing containing one or more anodes each of which is surrounded by a cylindrical cathode. In the annular space between an anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm supported from above by what is commonly referred to as the collector. The collector, or collector portion corresponding to a single anode comprises an outlet port for removal of the gaseous halogen and an annular inverted channel for manifolding and removal of the alkali metal. This collector is sup ported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the anodes with the surrounding diaphragm and cathode surface is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difficulties in the construction of these cells has been the lack of a suitable method for positioning the cathode, with respect to the anode, and for positioning the diaphragm located in the annular space between each anode and cathode. Because of the fact that the cathode and the diaphragm surround substantially the entire length of the anode, it is quite difiicult to position the diaphragm in between the cathode and anode within proper tolerances so as to provide the most efficient construction of the cell for operation. This can be appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches and for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode, which is about 3 to 4 feet or more in length. Prior method employed for achieving this result have not been adequate. Generally speaking, the life period, that is the period before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragms. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. A plant installation consists of a relatively large number of cells occupying specific floor positions or stalls. When a cell is necessarily replaced it unfortunately cannot be merely lifted from the production space or stall occupied, but must be torn down and rebuilt. During the time required for this dismantling and building of a new cell, the production space is, of course, unused.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher efliciency, and increased productivity. A particular object of this invention is to provide apparatus for gaging collectors for cells having four anodes and determining the existence of collector dimensions and relationship within desired tolerances. A further object is to provide apparatus for registering a gaged collector for assembly to a collector support frame in a predetermined spatial relationship. A specific object is to provide apparatus for assembling the collector to the collector frame in accurate alignment so that when inserted into the cell housing, proper positioning of a multi unit cathode With respect to the anodes and the diaphragms is within prescribed tolerances. A further object is to provide apparatus for providing a further gaging of a collector for determining its suitability for reception of diaphragms, and also for locating a set of diaphragms by a predetermined pattern and assembling to a collector-collector support frame sub-assembly. A still more specific object is to provide apparatus for the construction of an electrolytic cell which combines the several parts into accurately constructed sub-assemblies, and further provides for accurate joinder of these sub-assemblies into the ultimate cell. Other objects will be apparent from the discussion hereinafter.

The above and additional objects of this invention are provided by the apparatus described herein. The apparatus includes a device for gaging a collector with respect to the plan disposition of four cylindrical collector ports therein, and concurrently registering the collector and a collector support frame for establishing a cell sub-assembly. This apparatus is desirably employed in combination with a further apparatus which provides a secondary gaging of the collector, particularly with respect to the roundness of the collector ports, and further concurrently positions a set of diaphragms vertically and horizontally and provides for their assembly to a collector-collector support frame sub-assembly. In a still more specific embodiment of the invention the foregoing apparatus operates in conjunction with further apparatus for positioning the actual anodes of a cell, for positioning the cathode unit with respect to the anode, and for establishing reference assembly marks to provide for assembly of a collector-collector support frame-diaphragms assembly in predetermined spatial relationship to an assembly comprising the other major components of a cell, viz., the anodes and cathode unit.

It has been found that the apparatus of this invention provides an efiicient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathode with respect to the anodes, and the diaphragms with respect to the cathode and anodes, is achieved. The apparatus eliminates incorrect alignment of these integral parts which results, for example, in burning of the diaphragms causing loss of production and necessitating dismantling for reconstruction. Further, the efficiency of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In addition, the average life of the diaphragms is appreciably increased, thereby reducing loss in production time.

The apparatus is capable of assuming a variety of forms which will be readily understood from the details described below and the accompanying figures, including FIGURE 1 which shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to the several major components or sub-assemblies of a cell, and

FIGURE 2 is an isometric partially sectioned view of apparatus, which we term herein jig B, for further gaging of the collector and for positioning the cell diaphragms to the collector-collector frame sub-assembly,

3 this figure showing a portion of the collector support frame in operative position, and

FIGURE 3 is a detailed isometric sectioned view of a portion of the mechanism of a dummy anode forming a part of jig 13, showing a diaphragm in operative position, and

FIGURE 4 is an isometric, partially sectioned view showing the upper portion of the operative mechanism of the dummy anode depicted in FIGURE 9, and

FIGURE is a partially sectioned, elevation view of the assembly of diaphragms with the collector-collector support frame sub-assembly, shown in operative position in jig B.

The construction of a completed cell includes two major assembly sequences, the assemblies so-made then being combined into a completed cell. One sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assembly, and then the addition of diaphragm screens to that sub-assembly to form one of the two major assemblies cited above. The other sequence of assembly operations includes the addition of anodes to a cell base, then the addition of cell shell portion, a cathode, and an upper or final cell shell portion to form the second major assembly.

The above described assembly operations are schematically illustrated by FIGURE 1 which shows the fiow" of separate cell components into sub-assemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to FIG- URE 1, a set of anodes and a cell base are combined, using jig C. A cell shell portion, and part of the cell lining are then added, and a cathode is then fitted to this base sub-assembly using a jig D to provide proper spatial relations. To this assembly is added an upper cell shell using jig E for correct alignment.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using jig A. This subassembly and a set of diaphragms are then combined in another apparatus jig B, to complete the collector-collector frame-diaphragm assembly. This assembly is then transported in a transport jig F and is combined with the base assembly to form a completed cell.

A particularly effective apparatus for attaching the diaphragms and extending the spatial relations established in the collector-frame sub-assembly is jig B. This jig B is shown in FIGURE 2. A detail of a portion of one of the four dummy anodes 83 83 83 83 forming part of jig B, is shown by FIGURE 3. A further detail of an upper portion of a dummy anode is shown in FIG- URE 4.

A partially sectioned isometric view of jig B is given by FIGURE 2. Referring to FIGURE 2, the major components of jig B include an immovable enclosing frame structure 71, said frame including a base 72, rigid side walls 73 or columns, and an upper level plate 74. In this particular embodiment the upper level plate 74 supports a rigidly atfixed ring member or ring frame 75 corresponding in diameter to the shell of a completed cell. Attached to the ring frame 75 are two support members or Zbars 76 76 diametrically opposite, and having scribed registration marks or notches 77 77 In addition to the registration notches 77 77 in the Z-bars 76 76 a second pair of registration marks 79,, 79 is provided on a line at right angles to the line defined by the primary registration notches 77 77 The secondary registration marks 79,, 79 are scribed on machined pillow blocks 78 78 attached to the upper surface of the ring member 75.

The jig B includes a diaphragm aligning mechanism 81. This apparatus includes a base or foundation portion 82 upon which is rigidly mounted a set of four diaphragm aligners or dummy anodes 83 83 83 83 In plan,

these dummy anodes are centered on the corners of a square having a center corresponding identically with the point of intersection of the lines established by the pairs of registration marks 79 79 and registration notches 77 77 above the ring member 75. In addition to being positioned as indicated in a horizontal plane, the dummy anodes 83 are positioned with precise vertical alignment.

Description of the operative details of one of the dummy anodes 83 will be of value before describing the use and overall operation of jig B. FIGURE 3 is a partially sectioned isometric elevation of a lower portion of a dummy anode showing some of the operating mechanism incorporated therein, and a segment of a diaphragm 99. Referring to FIGURE 3, the principal elements of a dummy anode include a base member 85, an inner cylindrical member 86, rigidly mounted on the base member 85, and an outer cylindrical member 87 corresponding approximately in dimensions to an anode in a completed cell. Rigidly affixed to the outer cylinder 87 at about the lowest extremity thereof is a bevelled collar 88, which serves as a supporting shoulder for a cylindrical diaphragm 99, supported on a ferrule or reinforcing ring 98.

The outer cylinder 87 is supported by arms 89 which are attached to a threaded collar 90, engaging a threaded sleeve 91. The threaded sleeve is supported and later-ally positioned on a bearing, not shown, and is attached to a ring gear 92. A shaft 94 is journalled in the base member and supports a pinion gear 93 which meshes with the ring gear 92, rotation being caused by a hand wheel mounted on the external end of the shaft 94. It will be seen that rotation of the shaft 94 by the hand wheel 95 will cause rotation of the ring gear 92 and the threaded sleeve 91, which will in turn result in vertical displacement of the outer cylindrical member 87. In addition to the described mechanism for providing vertical movement of the outer cylinder 87, separate mechanism is provided for transmitting rotary motion to aligning means in the upper portion of a dummy anode, said means being described hereafter. This mechanism includes a second hand wheel 96 operating a stub shaft 97 which mounts or supports a bevel pinion gear 101. The stub shaft is positioned by stationary bearings, not shown. A bevel pinion gear 102 mates with the primary gear 101, and is keyed to a centrally positioned shaft 103. The shaft 103 terminates with an internally splined section 104 which mates with a splined end of a shaft 105, this shaft extending to the top portion of the dummy anode 83. These shafts 103, 105 are journalled by bearing means not shown. It is seen that rotative motion can be applied to the vertical shaft 105 concurrently with vertical motion.

The above described mechanism in the lower portion of the dummy anode serves to laterally position the lower end of a diaphragm 99 and also to raise a diaphragm to a desired elevation. In addition, means in the upper portion of a dummy anode provide for lateral registration of the upper extremity of a diaphragm. These means are illustrated by FIGURE 4, which shows a partially sectioned isometric elevation of the upper portion of a dummy anode 83.

Referring to FIGURE 4, the upper portion of a dummy anode 83 is shown and includes a cap plate 107, the extremities of the inner cylinder 86, the outer cylinder 87, and a portion of a splined shaft 105. A segment 106 of the splined shaft 105 engages and supports a threaded collar 108, which is press fitted into a shouldered recess in a three membered spider 109. The spider includes three arms 110. Extending upwardly at the ends of the spider arms 110 are two pin supports 111, the outer edges of the pin supports 111 making sliding contact with the inner wall of the inner cylinder 86. A stationary spider 112, positioned directly above the movable spider 109, has corresponding arms 113 extending through notches 114, 115 in the inner cylinder 86 and the outer cylinder 87, respectively. It should be noted that this spider 112 is stationary with respect to the outer cylinder 87, which is, as already noted, movable vertically.

Resting on the stationary spider arms 113, and slidable in a bearing space provided by the spider arms 113, the cap plate 107, and the slots 115 in the outer cylinder 87 are three aligning blocks 116, provided with inclined slots 117 at the inner ends. Retainer pins 118 passing through holes in the pin supports 111 position the aligning blocks 116 with respect to displacement from the center of the assembly. It will be seen that rotation of shaft 105 causes vertical movement of the threaded collar 108, movable spider .109, pin supports 111 and retainer pins 118. Upward movement of this assembly results in equal retraction of the aligning blocks 116 from the outside toward the shaft 105. Downward movement of the movable spider assembly caused equal outward movement of the aligning blocks. In operation, a diaphragm 99, having a top ferrule 100 is slipped over the dummy anode, and the aligning blocks 116 are moved outwardly until contact is made with the inner surface of the ferrule 100, the diaphragm being thus laterally positioned at the top.

From the foregoing, and adverting again to FIGURE 2, it is seen that jig B provides for lateral and vertical positioning of the diaphragms of a cell, operating firstly on the bottom of a diaphragm, and in addition, laterally positioning the top of the diaphragm. These operations provide alignment of the diaphragms of the cell in a predetermined relationship one to the other and also with reference to the collector and collector frame subassembly, and attachment of the diaphragms thereto is made using jig B. The interrelation of the diaphragms 99 and the collector-collector frame sub-assembly in jig B is shown by FIGURE 2 and FIGURE 5. Referring to FIGURE 2, a segment of a collector support frame 51 is shown, resting on the support bar 76. Further relationship of the collector-collector support frame sub-assembly and jig B is shown by FIGURE 5, this figure being a partially sectioned elevation showing a sectional view of a collector support frame 51 in place above the ring frame 75 of jig B, and supporting the collector 41. A portion of the collector casting 41 is shown in section, illustrating the mode of establishing connection between a diaphragm 99 and the collector. In establishing this assembly, the lower end of the diaphragm 99 is laterally positioned by the engagement of the band 98 with the bevelled collar 88. The aligning blocks 116 in the upper portion of the dummy anode 83 are then extended to laterally position the diaphragm ferrule 100. The outer cylinder '87, with the thus horizontally and vertically located diaphragm is then raised to establish initial contact with the bottom of a collector port wall. This operation permits a secondary gaging of the collector, this time with respect to the roundness of the individual collectors. If full circumferential contact is not possible with each diaphragm ferrule, the collector is rejected. The diaphragm ferrule is then fastened to the collector by a plurality of cap screws 122 inserted through a lug 121 and engaging a tapped hole in a boss or lug 123 projecting from the collector port Wall 42 The aligning blocks 116 are then retracted so that the collector-collector support frame-diaphragm assembly can be lifted from jig B when desired.

In those instances in which the lateral plane of the diaphragm 99 is at exactly right angles to the center line of the diaphragm cylinder, the diaphragm ferrule :100 will engage the entire periphery of the collector port wall 42 Frequently, however this precise relationship does not exist and compensating means are necessary to prevent stress and deformation of the diaphragm ferrule 100 and consequently deformation of the diaphragm screen proper. Accordingly, tapered washers 124 are provided for insertion between the ferrule lugs 121 and the mating lug 123 on the collector port wall. These washers take the major thrust of the cap screws 122 and prevent the deformation mentioned.

The foregoing describes the use of the apparatus of the invention or the preparation of collector-collector frame sub-assembly and the assembly of that sub-assembly with the diaphragms, thus forming a unit adaptable for precise insertion into a previously built cell base with anodes.

In a preferred embodiment of the invention, the jigs A and B are employed also in conjunction with additional devices for construction and assembly of the aforementioned cell base and cell shell as will be described hereafter. The general sequential relationships in this embodiment are illustrated again by FIGURE 1, wherein is shown the schematic combination of anode sticks and a cell base, employing a jig C, thus forming a base subassembly. To this is combined a cathode casting, its relationship to the base-anode sub-assembly being ascertained and determined by jig D, and a cell shell being then provided, its relationship to the preceding sub-assembly being determined by a jig E.

From the foregoing, it will be seen that by the described apparatus that a continuous explicit relationship of the collector frame, collector, diaphragms, anodes, and other portions of a cell are established and preserved through to this final assembly step. Further steps to render the cell operable would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

From the foregoing, it is seen that the objects of the invention are fully attained, particularly in the embodiment employing all six units described for the assembly thereof. It will also be understood that the most significant benefits arise from the use of jig A and jig B in establishing the assembly of collector, collector support frame, and diaphragms and in gaging the collector.

In a careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in current efficiency. In addition, it was found that the average effective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, what we claim is:

1. Apparatus for the assembly of a plurality of cylindrical diaphragms upon the ports of the collector of a collector-collector support frame sub-assembly of an electrolysis cell, said collector having substantially cylindrical, downwardly opening ports for engaging the tops of the cylindrical diaphragms, and the collector support frame being located upon a normally horizontal plane having the collector atfixed thereto in predefined relation with reference to two pairs of registration marks in said frame, said registration marks defining the intersection of two vertical planes, comprising an immovable enclosing frame, a ring frame and a plurality of diaphragm transport and aligning mechanisms, said immovable enclosing frame having a fixed base and rigid side walls which support an upper level plate to which is affixed the said ring frame, and upon the base of the said immovable enclosing frame are mounted a plurality of diaphragm transport and alignment devices as hereinafter defined, the immovable enclosing frame being stationary with respect to the base, the ring frame having top receiving surfaces for receiving and supporting the collector-collector support frame sub-assembly above its base, and in a horizontal,

vertically registered plane, and further having registration marks defining the intersection of two vertical planes whereby the collector-collector support frame sub-assembly can be laterally as well as vertically aligned with respect to the said immovable enclosing frame, base, and diaphragm transport aligners, the diaphragm aligners being mounted on the said base in fixed lateral disposition with reference to the said intersection of two vertical planes and corresponding in position to the anodes of a completed cell, each diaphragm transport aligner including a vertically movable outer cylindrical member adapted to support a diaphragm by engaging the bottom thereof, and to laterally position the bottom of a diaphragm by such engaging, elevating means for supporting, and changing the elevation of said section, at least three radially extending center blocks also supported on said elevating means and positioned above the outer member a distance corresponding generally to the length of a cylindrical diaphragm, extension means for radially extending the said blocks in unison to engage and laterally position the upper ends of a diaphragm, whereby a diaphragm can be vertically aligned and elevated to a predetermined level for attachment to a collector.

2. In an apparatus for the assembly of a plurality of cylindrical diaphragms upon the ports of the collector of a collector-collector support frame sub-assembly of an electrolysis cell, said collector having substantially cylindrical, downwardly opening ports for engaging the tops of the cylindrical diaphragms, a diaphragm transport and alignment mechanism comprising a base, an inner cylindrical member rigidly and vertically mounted on the base, and an outer axially movable cylindrical member coaxial with said inner member, said outer member being actuated by an elevating mechanism, and said outer member also having a bottom rim section attached thereto, said rim extending beyond the periphery of the said cylinder to engage the lower portion of a diaphragm to retain it in vertical position and said cylinder having apertures adjacent its upper extremity for extension means which complete the vertical alignment of the said diaphragm, said extension means consisting of at least three radially positioned centering blocks, horizontally positioned in said apertures which are supported on the said elevating means, and extension means for laterally extending in unison the said centering blocks independent of their vertical elevation, so as to engage and laterally position the upper end of a cylindrical diaphragm until it is concentric with the said outer member, whereby the vertically aligned cylindrical diaphragm can be elevated for attachment to a collector port.

3. In an apparatus for the assembly of a plurality of cylindrical diaphragms upon the ports of the collector of a collector-collector support frame sub-assembly of an electrolysis cell, said collector having substantially cylindrical, downwardly opening ports for engaging the tops of the cylindrical diaphragms, a diaphragm transport and alignment device comprising a base, an inner cylindrical member rigidly and vertically mounted on the base, and an outer axially movable cylindrical member coaxial with said inner member, said outer member being actuated by an elevating mechanism, and said outer member also having means at its lower extremity for retaining the lower portion of a diaphragm in vertical position and means at its upper extremity for completing the vertical alignment of the said diaphragm, said means at the upper extremity of the outer member consisting of at least three, radially positioned projectable members, which are supported on the said elevating means, and extension means for laterally extending in unison the said projectable members independent of their vertical elevation, so as to engage and laterally position the upper end of a cylindrical diaphragm until it is concentric with the said outer member, whereby the vertically aligned cylindrical diaphragm can be elevated for attachment to a collector port.

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